CHAPTER 33 Charging System

TVET PROGRAM TITLE: Vehicle Servicing And
Repairing Level II
Unit of Competence: Testing and Repairing

Engine Electrical Systems
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only
 Basic charging system parts
 Charging system functions
 Types of charging systems
 Alternator operation
 Alternator construction
 Charge indicators
Charging System Parts
 Alternator
 generator that uses mechanical
power to produce electricity
 Voltage regulator
 controls the output voltage of the
alternator
 Alternator drive belt
 links the engine crankshaft pulley
with the alternator pulley
 drives the alternator
Charging System Parts
 Charge Indicator
 ammeter, voltmeter, or warning light
 informs driver of the charging
system condition
 Harness
 wiring connecting the parts of the
system
 Battery
 provides current to initially
energize the alternator field
Charging System
Recharges the
battery and supplies
electricity when the
engine is running
 Recharges the battery after cranking
 Supplies the car’s electricity when the
engine is running
 Provides an output voltage slightly
higher than the battery voltage
 Changes the output to meet varying
loads
 Two types:
 DC generator
 AC generator (alternator)
DC Generator
 Similar to an electric motor
 Stationary magnetic field
 The output conductor unit (armature)
spins inside the field
 Induces current from within the
armature
AC Generator
(Alternator)
 Advantages:
 more efficient
 smaller and lighter
 more dependable
 more output at idle
AC Generator
(Alternator) Theory
 The magnetic field rotates
 The output conductors (windings) are
stationary
 The field rotates, inducing current in the
output windings
Generator
versus
Alternator
 Two main parts, rotor and stator
 The rotor is located in the center
 creates a rotating magnetic field when
turned by the drive belt
 The stator is a stationary set of
windings surrounding the rotor
 output winding in the alternator
Alternator Operation
 When the rotor spins, its strong

magnetic field cuts across the stator
windings
 Current is induced in the stator
windings
Alternator
Operation
AC Output
 Alternating current flows one way, then
the other
 As the rotor turns into one stator
winding, current is induced
 When the same rotor pole moves into
the other stator winding, the current
reverses direction
Rectified AC Current
 An automobile’s electrical system
requires direct current (DC), which
flows one way
 Alternator output must be rectified
(changed) from AC to DC
 A diode allows current flow in only one
direction
 Several diodes are connected into a
rectifier circuit
Diode
Acts as a one-way electrical check
valve
Diode Operation
Rotor
 Field windings mounted on a shaft
 Two claw-shaped pole pieces surround
the windings, increasing magnetic field
 The fingers on one pole piece produce
south magnetic poles
 The fingers on the other pole piece
produce north magnetic poles
Rotor Operation
As the rotor spins, alternating polarity
produces alternating current
Slip Rings
 Mounted on the rotor shaft

 Provide current to the rotor windings
 An external source of electricity is
needed to excite the field
Brushes
 Ride on the slip rings
 Provide a sliding electrical connection
 Feed battery current into the slip rings
and rotor windings
 Springs hold the brushes in contact
with the slip rings
Brushes and Slip
Rings
Rectifier
 Six diodes convert stator output to
direct current
 Provides full-wave rectification
 Changes both positive and negative
outputs into direct current
 Diode trio may be used to feed power
from the stator to the field (rotor)
Charging Circuit
Stator
 Three groups of windings wrapped
around a soft, laminated iron core (ring)
 Produces an electrical output
 The iron core concentrates the field
around the windings
Stator and Rectifier
A rectifier consists of
six diodes,
connected to the
stator windings
Y-Type Stator
 The wire ends from the three windings
are connected to a neutral junction
 Looks like a letter “Y”
 Provides good output current at low
speeds
Delta-Type Stator
 The stator wires are connected end to
end
 Two circuit paths are formed during
each phase of operation
 Provides high output
Alternator Wiring
Alternator Fan
 Mounted on the front of the rotor shaft
 Draws air through and over the
alternator
 Cools the windings and diodes
Pulley and Belt
The crankshaft turns the alternator belt
Types of Belts
Voltage Regulator
 Controls the alternator output voltage
 Changes the amount of current flowing
through the rotor windings
 The engine control module (ECM or
PCM) may serve as the voltage
regulator
Internally Regulated
Alternator
Voltage Regulators
Electronic Voltage
Regulator Operation
 To increase the alternator output, the
regulator allows more current into the
rotor windings
 The magnetic field around the rotor is
increased
 More current is induced in the stator
windings, increasing output
Battery Thermistor
 Measures battery temperature
 Allows the charging system to alter
output as needed
 A cold battery requires more voltage for
charging than a hot battery
 Often mounted on the positive battery
cable
Computer Monitor and
Control
 The powertrain control module (PCM)
can supplement or replace the voltage
regulator
 The PCM can react to changing
operating conditions
 shuts the alternator off at wide-open
throttle for better acceleration
 accurately controls the charge rate,
allowing a smaller, lighter battery
Charging
System
Internally regulated
alternator
Charging
System
Note computer
monitoring, and
battery thermistor
Charging System
The PCM contains the regulator circuit
Fail-Safe Circuit
 Disconnects the alternator output if
voltage levels become too high
 Protects the on-board electronics
 Informs the driver of the operating
condition or output of the charging
system
 Types:
 warning light
 voltmeter indicator
 ammeter indicator
Charging Circuit
The warning light glows when the
alternator output drops to a specified
level
Voltmeter Indicator
 A battery has 12.6 volts when fully
charged
 Alternator output must be higher:
 13–15 volts
 A voltmeter shows the voltage
Ammeter Indicator
 Shows the current output in amperes
 Reads to the right if the battery is being
charged
 Reads to the left if the battery is
discharging
Charging Circuit
Basic connections
for an ammeter
indicator

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TVET PROGRAM TITLE: Vehicle Servicing And

Unit of Competence: Testing and Repairing

 When the rotor spins, its strong

 Mounted on the rotor shaft

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